Introduction to Engineering Design Comprehensive Study Guide

Table of Contents
Table of Contents Unit 1: Design Process
Brainstorming Solutions Design Process

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Unit 1: Design Process

Brainstorming Solutions
Brainstorming: A group technique for solving problems, generating ideas, stimulating creative thinking, etc. o Involves collecting ideas without regard to feasibility Rules for brainstorming o No criticism allowed o Work for quantity o Welcome piling-on o Allow free-for all o Individual descriptions for each? People must experience brain-drain before the innovative, creative ideas can surface. The more ideas, the more likely quality ideas for surface Piling-on: When a members idea produces a similar idea or an enhanced idea. Types of free-form brainstorming o Post-it notes o Free writing o Blurting out Forced association: Ideas created by mentally forcing the association of two seemingly unrelated items o Ex. Wine press + coin stamp = Moveable type press SCAMMPERR technique- start with a current solution that somehow addresses the problem you are investigating, then try to generate new and different approaches o Substitute something o Combine it with something else o Adapt something to it o Magnify or add to it o Modify it o Put it to some other use o Eliminate something o Rearrange it o Reverse it Mind mapping Brainstorming documentation o Have a note taker o Take photographs o Compile ideas after the session What to do if you get stuck brainstorming o Combine promising partial solutions 3

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Try a different brainstorming technique Try both individual and group research Do some more research

Design Process
Design: A generic term that refers to anything that was made by a conscious human effort. Also a process that is used to systematically solve problems Design Process: A systematic problem-solving strategy, with criteria and constraints, used to develop many possible solutions to solve or satisfy human needs or wants and to narrow down the possible solutions to one final solutions 12-Step design process o Define the problem o Brainstorm o Research and generate ideas o Identify criteria and specific constraints o Explore possibilities o Select an approach o Develop a design proposal o Make a model or prototype o Test and evaluate the design using specifications o Refine the design o Create or make solution o Communicate processes and results IED design process

Define the problem o Identify a problem o Validate the problem Who says it is a problem? Needs and wants Prior solutions o Justify the problem Is the problem worth solving? o Create design requirements (criteria and constraints) o Project proposal Generate concepts o Brainstorm possible solutions o Research o Apply STEM principles o Select an approach (decision matrix) o Assess technology needs o Design proposal Develop a solution o Consider design validity Function, aesthetics, ergonomics, safety, cost, environment, durability, ease of maintenance, etc. o Create detailed design solutions o Technical drawings Construct and test a prototype o Plan prototype testing- performance, usability, durability o Analyze test data Evaluate the solution o Reflect on design and recommend improvements o Optimize/redesign the solution Revise design documents o Project recommendations Present the solution o Document the project- project portfolio o Communicate the project- formal presentation

Introduction to Research
Research: The systematic study of materials and sources in order to establish facts and reach new conclusion Primary research 5

o Original research o Generates current information o Includes observation, experiments, surveys, and interviews o Analyzes, synthesizes, and evaluates all information and data Advantages of primary research o Directly applicable to the need o Can result in extremely detailed, accurate, and relevant information or data o Can result in new information that cannot be found in secondary sources o Expert knowledge Disadvantages of primary research o Time consuming o Requires extensive planning o Can be expensive o May depend on the participation of unreliable sources for results Secondary research o Look to see what has been written/done before on a topic o Published works: Books, journals, magazines, newspapers o Unpublished works: Business reports, operating manuals, web pages o Most common research Advantages of secondary research o Less time and little to no cost o Helps focus or expand your scope o Sense of credibility and authority in that it shows others the researcher has done their homework Disadvantages of secondary research o May have to go through a lot of information o Unauthoritative or unreliable sources Research libraries o Support researches o Extensive collections of book and journals, theses, dissertations, and other unpublished works Ways to tell the quality of a source o Authority: Creators qualifications o Reliability: Can you trust it to have accurate information? o Bias: How creators interests influence the information o Currency: How current the information is, and how important that is to the topic

Unit 2: Technical Sketching

Isometric and Oblique Pictorials
Pictorial drawing o 2D illustration of a 3D object o Shows three faces of an object in one view o Three types: Isometric, oblique, perspective Oblique pictorials o Starts with a straight-on view of one of the objects faces (often the front face) o Angled, parallel lines drawn to represent the objects depth o Common oblique angles: 30, 45, 60 Cavalier oblique: Represents the object with full depth. Tends to create the illusion that it is deeper than it actually is. Cabinet oblique: Represents the object with half depth, but provides a more realistic, less distorted view General oblique: represents an objects true width and height, but the depth can be any size and drawn at any angle Isometric pictorial o Three adjacent faces on a cube will share a single point o Edges converge at one point will appear as 120 angles or 30 from the horizon line o 3 edges represent height, width, and depth o Two different view orientations Top, front, right side (used in IED) Top, left side, front How to select the front view o Most natural position or use o Shows best shape and characteristic contours o Longest dimensions o Fewest hidden lines o Most stable and natural positions Good sketching requires a sense of proportion, and the ability to estimate size, distance, angles, and other spatial relationships

Sketching an Isometric Circle

1. Use points and construction lines to box the location of the circular face 2. Connect points with diagonal construction lines 3. Place marks at the midpoints of the diagonal lines, and 2/3 the distance from the box center to each outside corner

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Draw four individual construction line arc segments tangent to the marks that were created Draw an object line over the construction line ellipse Repeat for the other end of the cylinder Use construction lines to connect the two ellipses Tonal shading

Multi-view Sketching
Multi-view drawing o Shows two or more 2D views of a 3D object o Provides the shape description of an object o When combined with dimensions, serves as the main form of communication between designers and manufacturers Orthographic projection o Technique used to create multi-view drawings o Any projection of the features of an object onto an imaginary plane of projection Projection of the features of the object made by lines of sight that are perpendicular to the plane of the feature Projection plane (also plane of projection or picture plane): An imaginary surface between the viewer and the object. The surface onto which a 2D view of a 3D object is projected and created. Projection line: An imaginary line that is used to locate or project the corners, edges, and features of a 3D object onto an imaginary 2D surface Number of orthographic projections o One view Uniform thickness or shape Two views would be identical All dimensions properly and easily shown on one view o Two views Symmetrical part A third view would be identical to one other Second view is necessary for depth

Perspective Sketching
Perspective drawings o Offer the most realistic 3D view of all the pictorial methods, because they portray objects in a manner that is most similar to how the human eye perceives the world One-point perspective o Relatively simple to make, but somewhat awkward appearance o Horizontal line represents the horizon o One vanishing point is identified on the horizon line o Lines draw from distinctive points on the object to the vanishing point 8

Two-point perspective: Most common perspective drawing Three-point perspective: Gives worms eye or birds eye view of an object

Line Conventions
Construction line: Very lightly drawn lines to guide drawing other lines and shapes Object line: Thick and dark- defines the object Hidden line: Shows interior detail not visible from the outside of the part Center line: Define the center of arcs, circles, or symmetrical parts. Half as thick as an object line Section line: Defines where material is cut away Short-break line: Freehand drawn line. Shows where part is broken to reveal detail behind the part or to shorten a long continuous part Dimension line: Shows distance. Arrows drawn on ends to show where dimension line starts and ends Extension line: Shows where a dimension starts and stops. 1/16 away from part to avoid confusion with object lines Long break line: Shortens very long objects with uniform detail. Represented as a jagged cut or break Leader line: Shows dimensions of arcs, circles, and detail Precedence of lines o Object lines take precedence over hidden and center lines o Hidden lines take precedence over center lines o Cutting plane lines take precedence over all others

Unit 7: Documentation
Alternate Views
Section view o Provides a view of an object as if it were cut by a saw o Location is indicated by a cutting plane line on another view Cutting plane line o Indicates location of the cut o Thick and broken line 9

o Arrows indicate direction of view o Labeled with a letter for identification on drawing Section lines o Hatch lines that indicate material that was cut at the cutting plane line o Thin lines Types of section views o Full section Cutting plane line passes fully through the part The part of the object behind the cutting plane line (away from arrows) is removed o Half section Used on symmetrical parts to show inside as well as outside details in one view One quarter of the part is cut away Cutting plane line goes halfway through the part o Offset section Interior features not in line with each other can be shown in an offset section view Cutting plane line changes direction and follows the center of each feature Auxiliary views o Orthographic projection of an inclined plane (angled surface) which appears foreshortened in a principle orthographic projection o Used to show the true size and shape of an inclined plane and the features on it o Allows the viewer to look perpendicular to an angled surface to witness the true size and shape of that surface and its features Foreshortened surfaces do not give a clear or accurate representation of the size or shape of the surface or features and should not be dimensioned Detail views: An enlargement of a portion of another view to illustrate small features on a part (different than a detail drawing, which is any drawing that contains all the information needed to manufacture a part)

Dimensioning Standards
ANSI: American National Standards Institute. Creates the engineering standards for North America ISO: International Organization for Standardization. Worldwide organization that creates engineering standards with about 100 participating countries US military organizations that develop standards- Department of Defense (DoD) and Military Standard (MIL)

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DIN: Deutsches Institut fr Normung. The German Standards Institute created many standards used worldwide, including the standards for camera film. JIS: Japanese Industrial Standard. Created after WWII for Japanese standards CEN: European Standards Organization If the dimension text will not fit between the extension lines, it may be placed outside them Dimension text is placed in the middle of the line both horizontally and vertically Two dimensioning systems o Unidirectional: Dimensions place so they can be read from the bottom of the drawing sheet. Common in mechanical drafting o Aligned: Dimensions placed so the horizontal dimensions can be read from the bottom of a drawing sheet and the vertical dimensions can be read from the right side. Common in architectural and structural drafting Chain dimensioning: Dimensioning from feature to feature o Preferable method: Dimension from feature to feature except one feature, then dimension overall length/width/height Datum dimensioning: Dimensioning from a single point of origin (datum). Reduces dimensional deviations in manufactured parts because each size/location dimension is referenced to a single point Coordinate method of dimensioning angles: Specify the two location distances of the angle Angular method of dimensioning angles: Specifying one location for distance and the angle Arrows can be inside or outside for small arcs. Small arcs do not need a center mark, but large arcs do Fillet: An inside radius between two intersecting plane Round: An outside radius applied to corners Points are placed along the contour of splines and dimensioned from a datum

Documentation
Working drawings are a complete set of drawings that document how an object will be manufactured and assembled. Includes part drawings, assembly drawings, parts list, and specifications and instructions Part drawing o Consists of dimensioned orthographic views, and if necessary, section, auxiliary, and isometric Title block o Person who created it o Person who checked it o Quality assurance o Sheet # o Scale o Project name (instead of part) o Drawing number or specific part name 11

o Zoning o Person who approves it for manufacture o How many times drawing has been revised o Size of sheet o General notes and information Assembly drawings o Show how parts of a multi-component design fit together o Generally depict at least one orthographic projection o Full section views often show necessary internal features Types of assembly drawings o Design assembly: Shows relationships between components. Often based on preliminary design process sketches before the product is modeled o General assembly: Most common type of assembly drawing. Displayed as a multi-view drawing, sometimes with a section view. Not dimensioned o Detail assembly: Combines an assembly view with several parts as dimensioned multiview drawings on one sheet, which reduces the number of drawing sheets needed. More appropriate for designs with small numbers of components o Erection assembly: Similar to general assemblies, except dimensions and fabrication specifications are included. Used for cabinetry, products made from steel, fabrication, and assembly o Subassembly: Part of an assembly o Pictorial assembly: Usually an isometric or perspective drawing that may be rendered to imitate photographic quality. Uses include sales promotions, customer self-assembly, and maintenance procedures Exploded pictorial drawings commonly show how individual components fit together Balloon: A circle with a single number connected to an assembly component with a leader line o Balloons on a drawing are the same size o Grouped in an easy-to-read pattern o Correspond to item numbers in parts list o No horizontal or vertical leader lines Parts list: A table with information about each part contained in the assembly Items on a parts list o Item number from balloons o Quantity of a particular part needed for the assembly o Part or drawing number as reference to the detail drawing o Description o Material identification of part o Information about vendors Most commonly located above the title block

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Holes
Through/Thru: Hole cuts through entire thickness Clearance: Hole large enough to allow screw head (and driver) to pass through Blind: Hole does NOT cut through entire thickness Countersink: Conical-shaped recess around hole at surface. Often used to accept tapered screw Counterbore: Cylindrical recess around hole at surface. Often used to receive a bold head or nut Tapped: Hole has internal threads o ISO method M12-1.5 6H THRU [M for metric][Nominal diameter in mm]-[Pitch] [Grade of tolerance- whole # 39][H for no allowance, G for tight allowance] [THRU] (LH for left hand may be before thru) o Unified National Thread method 5/16-18 UNC [Major diameter]-[Thread per inch] UN[C for coarse, F for fine]

Technical Writing
Examples of technical writing include proposals, regulations, manuals, procedures, requests, technical reports, progress reports, emails, and memos Technical writing: A type of expository writing that is used to convey information to a particular audience for a particular technical or business purpose. o Not used to entertain, create suspense, or invite differing interpretations Technical reports: Communicate technical information and conclusions about projects to customers, managers, legal authority figures, and other engineers o ANSI provides technical report layout and format specifics 3 parts of a technical report o Front matter o Text o Back matter Front matter: Used to help potential readers find the report and certain parts of it o Front cover: Label identifies report title and subtitle, authors name, publisher, and date of publication o Title page: Provides descriptive information that is used by organizations that provide access to information resources. Duplicates information on the front cover o Abstract: A short summary that provides an overview of the purpose, scope, and findings contained in the report Purpose: identifies the issue, need, or reason for the investigation Scope: Reviews the main points, extent, and limits of the investigation Findings: Includes condensed conclusions and recommendations 13

Informative abstract: Identifies the issue or need that led to the report, reviews the main points and major findings, and includes condensed conclusions and recommendations. Descriptive abstract: Provides a description of the reports main topic and purpose, along with an overview of its contents. It presents the broadest view and offers no major fact. Often only a few sentences long and may be located at the bottom of the title page.

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